Quick change over tooling for a welder

ABSTRACT

A weld stack includes a horn having a weld end, a polar mount adapted to receive a portion of the horn therein, a first adjustment ring coupled to the polar mount at a pre-determined distance from the weld end of the horn, and a second adjustment ring coupled to the polar mount adjacent the first adjustment ring, wherein the second adjustment ring includes a fine adjustment device for adjusting a relative position of the first adjustment ring and the second adjustment ring.

FIELD OF THE INVENTION

The present invention generally relates to high frequency welding. Moreparticularly, the invention is directed to a welding assembly and amethod for a quick change-over of the welding assembly.

BACKGROUND OF THE INVENTION

Current ultrasonic welding systems are not equipped to support alarge-scale production facility. The frequency of failures of anultrasonic horn and the manner in which the horn fails is oftenunpredictable. Many of the failures create “emergency equipmentrepairs”, as well as extended downtime and a significant risk to acustomer's shipping schedule.

Current ultrasonic welding systems in the field do not accommodate quickchangeover features or standard datum features. Accordingly, there iscurrently no standardized and repeatable replacement set up for theultrasonic welding systems used in a production facility.

It would be desirable to develop a weld stack for an ultrasonic weldingsystem and a setup fixture for the same, wherein the weld stack andsetup fixture provide a means for a quick change over, a repeatablesetup, an objective polar adjustment, and a standard off-line initialsetup.

SUMMARY OF THE INVENTION

Concordant and consistent with the present invention, a weld stack foran ultrasonic welding system and a setup fixture for the same, whereinthe weld stack and setup fixture provide a means for a quick changeover, a repeatable setup, an objective polar adjustment, and a standardoff-line initial setup, has surprisingly been discovered.

In one embodiment, a weld stack comprises a horn having a weld end, apolar mount adapted to receive a portion of the horn therein, a firstadjustment ring coupled to the polar mount at a pre-determined distancefrom the weld end of the horn, and a second adjustment ring coupled tothe polar mount adjacent the first adjustment ring, wherein the secondadjustment ring includes a fine adjustment device for adjusting arelative position of the first adjustment ring and the second adjustmentring.

In another embodiment, a setup fixture for a weld stack comprises aframe, a spindle locator coupled to the frame for receiving a weldstack, a radial locator coupled to the frame for receiving a weld end ofa horn of the weld stack and positioning the horn in a desired radialposition, and a horn locator disposed adjacent the radial locator andabutting a polar mount of the weld stack, wherein the horn locatorfacilitates a standardization of a configuration of the weld stack.

The invention also provides methods for configuring a weld stack.

One method comprises the steps of: providing a setup fixture having aframe; providing a spindle locator coupled to the frame adapted topermit a polar mount of a weld stack to pass therethrough; providing ahorn locator coupled to the frame and abutting the polar mount of theweld stack, wherein the horn locator facilitates a standardization of aconfiguration of the weld stack; and providing a radial locator coupledto the frame for receiving a weld end of a horn of the weld stack andpositioning the horn in a desired rotational position.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, willbecome readily apparent to those skilled in the art from the followingdetailed description of the preferred embodiment when considered in thelight of the accompanying drawings in which:

FIG. 1 is a side perspective view of a weld stack according to anembodiment of the present invention, wherein the weld stack is shown ina vertical position;

FIG. 2 is a front perspective view of the weld stack of FIG. 1, whereinthe weld stack is shown in a horizontal position;

FIG. 3 is a front perspective view of a setup fixture for the weld stackof FIGS. 1 and 2;

FIG. 4 is a rear perspective view of the setup fixture of FIG. 3;

FIG. 5 is a left side perspective view of a mount for the weld stack ofFIGS. 1 and 2; and

FIG. 6 is a right side perspective view of the mount of FIG. 5.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The following detailed description and appended drawings describe andillustrate various embodiments of the invention. The description anddrawings serve to enable one skilled in the art to make and use theinvention, and are not intended to limit the scope of the invention inany manner. In respect of the methods disclosed, the steps presented areexemplary in nature, and thus, the order of the steps is not necessaryor critical.

FIGS. 1-2 illustrate a quick change weld stack 10 or ultrasonic stackaccording to an embodiment of the present invention. As shown, the weldstack 10 includes a polar mount 12 or sleeve, a horn 14, an accelerator16 or booster, a first adjustment ring 18, and a second adjustment ring20.

The polar mount 12 is a hollow tube having a generally cylindricalshape. However, any shape and size may be used. The polar mount 12 isadapted to receive at least one of the horn 14 and the accelerator 16therein. In the embodiment shown, the polar mount 12 includes aplurality of apertures for receiving at least one of a locator 22 and aplurality of set screws 24 for aligning the horn 14 as desired withinthe polar mount 12. As a non-limiting example, the locator 22 is mountedto an outside surface 26 of the polar mount 12, wherein a rounded end 28of the locator 22 extends through the polar mount 12 to engage the horn14. It is understood that the locator may have a pre-determined size foraligning and positioning the horn 14 within the polar mount 12. As afurther non-limiting example, the polar mount 12 receives three setscrews 24, each of the set screws 24 having a flat end for engaging thehorn 14. It is understood that the polar mount 12 may include any numberof apertures and through-holes for receiving any number of set screws 24and locators 22.

The horn 14 includes a main body 30 having a welding end 32. The horn 14is coupled to the accelerator 16 to provide a pre-determined motion orvibration thereto. As a non-limiting example, the horn 14 is driven atultrasonic frequency levels. In the embodiment shown, the horn 14 andaccelerator 16 are received in the polar mount 12. The horn 14 includesa datum structure 33 such as an indentation for receiving the locator 22and positioning the horn 14. As a non-limiting example, the datumstructure 33 is positioned on the main body 30 of the horn at a nodalpoint. However, any number of datum structures may be used to align thehorn 14 as desired within the polar mount 12.

The first adjustment ring 18 is disposed around the outside surface 26of the polar mount 12. The first adjustment ring 18 is typically a splitcollar having a coupler 34 for adjusting an interior diameter ofthereof. As shown, the coupler 34 is a quick coupler having a couplingskewer 36 disposed through a split portion of the first adjustment ring18. One end of the coupling skewer 36 includes an adjustment nut 38 andan opposite end of the coupling skewer 36 includes a cam lever 40. It isunderstood that the adjustment nut 38 and the cam lever 40 cooperate toadjust the interior diameter of the first adjustment ring 18. It isfurther understood that any means for adjusting the interior diameter ofthe first adjustment ring 18 may be used, and that any type adjustmentring can be used.

The first adjustment ring 18 also includes an adjustable width channel42 formed in an outside edge 44 of the first adjustment ring 18. Aflexible tab 46 is disposed adjacent the channel 42 and adapted toreceive a “flex” force from a plurality of pins 48 or set screws. Forexample, the pins 48 exert a force on the tab 46 to adjust a dimensionof the channel 42. As a further example, the tab 46 is formed in theoutside edge 44 of the first adjustment ring 18. It is understood thatany number of pins may be used to exert a force on the tab 46 to adjusta width of the channel 42. It is further understood that the channel 42may have any size and may be positioned in any location, and that anytype adjustment ring can be used.

The second adjustment ring 20 is disposed around the outside surface 26of the polar mount 12 and adjacent the first adjustment ring 18. Thesecond adjustment ring 20 is typically a split collar having a coupler50 for adjusting an interior diameter of thereof. As shown, the coupler50 is a threaded bolt or screw disposed through a split portion of thesecond adjustment ring 20. It is understood that any means for adjustingthe interior diameter of the first adjustment ring 18 may be used suchas quick couple device similar to coupler 34.

The second adjustment ring 20 also includes a fine adjustment device 52.As shown, the fine adjustment device 52 is a micrometer. Specifically, apin 54 is disposed in the first adjustment ring 18 and extends therefromin a direction of the second adjustment ring 20. An adjustment member 56of the fine adjustment device 62 is disposed through a portion of thesecond adjustment ring 20 and abuts the pin 54. A tension device 58(e.g. a spring loaded pin) is disposed in a portion of the secondadjustment ring 20 in alignment with the adjustment handle 56 andabutting the pin 54. A rotational motion of the adjustment handle 56exerts a force on the dowel pin to adjust a relative position of thefirst adjustment ring 18 and the second adjustment ring 20.

FIGS. 3-4 illustrate a setup fixture 59 for receiving the weld stack 10according to an embodiment of the present invention. The setup fixture59 includes a frame 60 having a base 62 and a back plate 64, a radiallocator 66, a horn locator 68, a spindle locator 70 and a clamp plate72.

The radial locator 66 is coupled to the base 62 and includes a channel74 for receiving the weld end 32 of the horn 14. The horn locator 68 iscoupled to the radial locator 66 and includes a horn channel 76 forreceiving at least a portion of the horn 14.

The spindle locator 70 is coupled to the back plate 64 and is adapted topermit a portion of the weld stack 10 to pass therethrough. The spindlelocator 70 also includes a pin 80 protruding from a surface thereof. Asa non-limiting example, the pin 80 is positioned to be received by theadjustable width channel 42 of the first adjustment ring 18.

The clamp plate 72 is a split collar having a coupler 82 for adjustingan interior diameter of thereof. As shown, the coupler 82 is a quickcoupler similar to the coupler 34. However, any means for adjusting aninterior diameter of the clamp plate 72 may be used.

When the setup fixture 59 is in use, the polar mount 12 is disposedthrough the spindle locator 70 and the clamp plate 72, wherein a portionof the polar mount 12 abuts the horn locator 68. The first adjustmentring 18 is disposed around the polar mount 12 and adjacent the spindlelocator 70. As a non-limiting example, the first adjustment ring 18 ispositioned to dispose the pin 80 into the adjustable width channel 42.The second adjustment ring 20 is disposed around the polar mount 12 andpositioned to receive the dowel pin 54 between the adjustment handle 56and the tension device 58. As a non-limiting example, the fineadjustment device 52 is set to a “zero” or mid-point position. It isunderstood that the first adjustment ring 18 and the second adjustmentring 20 may move relative to one another until one is sufficientlysecured to the polar mount 12.

The horn 14 and the accelerator 16 are disposed in the polar mount 12,wherein a portion of the horn 14 extends through the horn channel 76 andthe weld end 32 of the horn 14 is received in the channel 74 of theradial locator 66. It is understood that a size of the horn locator 68provides a standard for a position of the horn 14 relative to the polarmount 12. It is further understood that the radial locator 66 provides aradial alignment of the horn 14 within the polar mount 12.

Once the horn 14 is disposed in the polar mount 12, the rounded end 28of the locator 22 is aligned with the datum structure 33 of the horn 14and the locator 22 is coupled to the polar mount 12. The clamp plate 72is secured to the polar mount 12 by locking the cam lever 82. The firstadjustment ring 18 and the second adjustment ring 20 are each secured tothe polar mount 12. It is understood that a position of the firstadjustment ring 18 relative to the weld end 32 is standardized basedupon the dimensions of the setup fixture 59. The set screws 24 aretightened against the horn 14. As a non-limiting example, the back plate64 includes an aperture 83 to provide access to at least one of the setscrews 24 positioned adjacent the back plate 64. Once each of the setscrews 24 is secured, the weld stack 10 is removed from the setupfixture 59 for use.

FIGS. 5 and 6 illustrate a mount 84 for receiving the weld stack 10according to an embodiment of the present invention. As shown, the mount84 includes a housing 86 defining a cavity to receive the weld stack 10.A clamp 88 is disposed in the cavity and coupled to the housing 86. As anon-limiting example, the clamp 88 is an elongate split collar forreceiving and securing the polar mount 12 therein. The clamp 88 includesa plurality of couplers 90 for adjusting an interior diameter ofthereof. As shown, each of the couplers 90 is a quick coupler similar tothe coupler 34. The clamp 88 also includes a pin 92 protruding from asurface thereof. As a non-limiting example, the pin 92 is positioned tobe received by the adjustable width channel 42 of the first adjustmentring 18 of the weld stack 10. It is understood that any number ofcouplers 90 and any means for adjusting the interior diameter of theclamp 88 may be used. It is further understood that any mounting deviceand structure may be used to couple the weld stack 10 to any controlsystem such as a robotic system or robot arm, for example.

In use, the weld stack 10 is disposed in the clamp 88 wherein the firstadjustment ring 18 abuts a portion of at least one of the clamp 88 andthe housing 86. It is understood that the first adjustment ring 18 isspaced from the weld end 32 of the horn 14 based upon the pre-determineddimension of the setup fixture 59. Once the weld stack 10 is inposition, the couplers 90 of the clamp 88 are adjusted to secure theweld stack 10 therein.

The weld stack 10, the setup fixture 59, the mount 84, and the methodsaccording the present invention provide multiple benefits over the art.The present invention minimizes a need for hand tools, therebysimplifying a setup, change-over and replacement process and minimizinga required intervention of a higher level of support. The presentinvention provides a quick change over tooling so that the entire weldstack 10 can be changed out within minutes, thereby minimizing downtimeand maximizing production efficiency. The present invention alsoprovides an objective polar adjustment. The weld stack 10, the setupfixture 59, and the mount 84 provides the operator with a baselineposition and an objective measurement system to make future adjustments.Specifically, the horn 14 includes the datum structure 33 to minimizecritical stress risers, minimize unwanted downtime, simplify areplacement of the horn 14 and make a resultant weld substantiallyrepeatable after a changeover.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

1. A weld stack comprising: a horn having a weld end; a polar mount adapted to receive a portion of the horn therein; a first adjustment ring coupled to the polar mount at a pre-determined distance from the weld end of the horn; and a second adjustment ring coupled to the polar mount adjacent the first adjustment ring, wherein the second adjustment ring includes a fine adjustment device for adjusting a relative position of the first adjustment ring and the second adjustment ring.
 2. The weld stack according to claim 1, further comprising a locator coupled to the polar mount, wherein the locator includes a rounded end to engage the horn.
 3. The weld stack according to claim 1, wherein the horn includes a datum structure to cooperate with a locator.
 4. The weld stack according to claim 1, wherein at least one of the first adjustment ring and the second adjustment ring is a split collar.
 5. The weld stack according to claim 1, wherein at least one of the first adjustment ring and the second adjustment ring includes a quick coupler for adjusting an interior diameter thereof.
 6. The weld stack according to claim 1, wherein the first adjustment ring includes a channel formed thereon to receive a pin for aligning the weld stack.
 7. The weld stack according to claim 6, wherein the first adjustment ring includes a flexible tab disposed in the channel to adjust a dimension of the channel.
 8. The weld stack according to claim 1, wherein the fine adjustment device is a micrometer disposed for exerting a force on an alignment pin protruding from a surface of the first adjustment ring to adjust a relative position of the first adjustment ring and the second adjustment ring.
 9. The weld stack according to claim 1, wherein the horn is in communication with an accelerator and at least a portion of the accelerator is received by the polar mount.
 10. A setup fixture for a weld stack, the setup fixture comprising: a frame; a spindle locator coupled to the frame for receiving a weld stack; a radial locator coupled to the frame for receiving a weld end of a horn of the weld stack and positioning the horn in a desired radial position; and a horn locator disposed adjacent the radial locator and abutting a polar mount of the weld stack, wherein the horn locator facilitates a standardization of a configuration of the weld stack.
 11. The setup fixture according to claim 10, wherein a portion of the frame includes an aperture to facilitate access the weld stack.
 12. The setup fixture according to claim 10, wherein the spindle locator includes a pin protruding from a surface thereof for positioning the weld stack in a desired orientation.
 13. The setup fixture according to claim 12, wherein the weld stack includes a channel formed therein for receiving the pin protruding from the spindle locator.
 14. The setup fixture according to claim 10, wherein the horn locator is positioned a pre-determined distance from the spindle locator to facilitate a standardization of a configuration of the weld stack.
 15. The setup fixture according to claim 10, further comprising a clamp plate coupled to the frame to secure a position of the polar mount of the weld stack relative to the setup fixture.
 16. A method for configuring a weld stack, the method comprising the steps of: providing a setup fixture having a frame; providing a spindle locator coupled to the frame adapted to permit a polar mount of a weld stack to pass therethrough; providing a horn locator coupled to the frame and abutting the polar mount of the weld stack, wherein the horn locator facilitates a standardization of a configuration of the weld stack; and providing a radial locator coupled to the frame for receiving a weld end of a horn of the weld stack and positioning the horn in a desired rotational position.
 17. The method according to claim 16, wherein the spindle locator includes a pin protruding from a surface thereof for positioning the weld stack in a desired orientation.
 18. The method according to claim 17, wherein the weld stack includes a channel formed therein for receiving the pin protruding from the spindle locator.
 19. The method according to claim 16, wherein the horn locator is positioned a pre-determined distance from the spindle locator to facilitate a standardization of a configuration of the weld stack.
 20. The method according to claim 16, further comprising the step of securing a position of the polar mount and the horn of the weld stack relative to the setup fixture. 